Motor Drive Module Direct Coil Connection
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Solution Overview
Problem
Conventional motor devices are limited in size reduction due to the need for large printed circuit boards to supply currents to semiconductor modules and coils, and the requirement for space to accommodate welding jigs for connecting coil terminals and coils.
Innovation Solution
An electronic circuit-integrated motor device with a semiconductor module that includes a switching element, a resin part, and a coil terminal, where the coil terminal protrudes from the resin part and is connected directly to the coil, eliminating the need for a printed circuit board and allowing for a more compact design by positioning the connection part between the motor case's end wall and the resin part's bottom wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If semiconductor modules are connected to coils through a printed circuit board, then electrical connection is achieved, but the motor device size increases due to the large area required for copper films
Solution Approach 1:
The invention extracts and eliminates the printed circuit board from the system by providing coil terminals that protrude directly from the resin part of the semiconductor module, enabling direct connection to the coils without requiring a separate printed circuit board for electrical connection
Solution Approach 2:
The invention merges the coil terminal function directly into the semiconductor module structure by having the coil terminal protrude from the resin part, combining the semiconductor module and connection terminal into a single integrated component
2Reliability
If coil terminals are connected between the motor and semiconductor modules, then direct electrical connection is achieved, but space is required for placing a welding jig which prevents size reduction
Solution Approach 1:
The invention changes the spatial arrangement by positioning the connection part of the coil terminal in the axial direction between the end wall and the resin part's bottom wall surface, utilizing the axial dimension to accommodate the connection without increasing the radial or lateral dimensions
Solution Approach 2:
The invention nests the connection part within the axial space already defined by the motor structure, positioning it between the end wall and the resin part bottom wall surface, effectively utilizing existing structural space
Data Source
AI summary
A motor case is formed in a tubular shape. A semiconductor module includes a semiconductor chip of switching elements, a resin part and a coil terminal. The resin part embeds the semiconductor chip therein. The coil terminal is protruded from the resin part and directly connected to a coil. A connection part between the coil terminal and the coil is arranged at a position, which is between a top wall surface and a bottom wall surface of the resin part facing each other in the axial direction of a motor.